Aeration device and method for assisting discharge of material from containers

ABSTRACT

An aeration device and method for assisting discharge of material from containers, comprising a cone shaped support adapted to be affixed to a wall of a container and to extend into the interior of the container, said device having an air inlet at one end thereof adapted to be connected to a source of air exteriorly of the container and an air outlet at the other end thereof interiorly of the container, a flexible, cone shaped flap shaped complementary to the support and secured thereon in close fitting relationship therewith closing said air outlet interiorly of the container, and having an open, large diameter end adjacent the container wall free of attachment to said support for flexing movement thereof toward and away from the support to close and open said air outlet, whereby flow of air through said support and outwardly through said outlet induces flexation of said large diameter end of said flap away from said support and flow of air toward the container wall and into material stored in the container to aerate the material, said flap being caused to flutter or vibrate by air flowing therepast to prevent bridging of the material in the container and to insure substantially complete removal of the material from the container.

United States Patent [1 1 Solimar Dec. 30, 1975 [75] Inventor: Keith F.Solimar, New Brighton,

Minn.

[73] Assignee: Butler Manufacturing Company,

Kansas City, Mo.

22 Filed: Feb. 4, 1974 21 Appl.No.:439,530

[52] U.S. CI. 222/195; 302/53; 259/DIG. 17 [51] Int. CI. B65G 3/12 [58]Field of Search 222/193, 195, 196, 202,

222/216, 200, 198, 226; 302/52, 53; 259/3646, DIG. 17, DIG. 43; 137/525,525.3

OTHER PUBLICATIONS Airnetics, Incorporated, Bulletin No. 104, Sept.1972.

Primary Examiner Robert B. Reeves Assistant Examinerl-l. Grant SkaggsAttorney, Agent, or FirmShoemaker and Mattare [57] ABSTRACT An aerationdevice and method for assisting discharge of material from containers,comprising a cone shaped support adapted to be affixed to a wall of acontainer and to extend into the interior of the container, said devicehaving an air inlet at one end thereof adapted to be connected to asource of air exteriorly of the container and an air outlet at the otherend thereof interiorly of the container, a flexible, cone shaped flapshaped complementary to the support and secured thereon in close fittingrelationship therewith closing said air outlet interiorly of thecontainer, and having an open, large diameter end adjacent the containerwall free of attachment to said support for flexing movement thereoftoward and away from the support to close and open said air outlet,whereby flow of air through said support and outwardly through saidoutlet induces flexation of said large diameter end of said flap awayfrom said support and flow of air toward the container wall and intomaterial stored in the container to aerate the material, said flap beingcaused to flutter or vibrate by air flowing therepast to preventbridging of the material in the container and to insure substantiallycomplete removal of the material from the container.

6 Claims, 10 Drawing Figures FIGS.

US. Patent Dec. 30, 1975 FIG .5.

Sheet 2 of 2 AERATION DEVICE AND METHOD FOR ASSISTING DISCHARGE OFMATERIAL FROM CONTAINERS BACKGROUND OF THE INVENTION The presentinvention relates to a device and method for introduction of air intodry bulk material to fluidize or condition the material for efficientpneumatic transfer. The device can also be used to introduce air intoliquid slurry solutions to keep solids in suspension and provideunloading pressures for the slurry solutions.

The device of the invention is used in pneumatic trailer tanks, railcars, storage tanks and the like and functions as a check valve whenused in relation to dry and liquid product storage.

Various devices are known in the prior art for introducing air intocontainers to aerate material stored in the containers. However, suchdevices are either porous, and thus not capable of functioning as acheck valve, or they do not vibrate and do not cause as efficientaeration of the material as does the present invention.

The present invention is a device for use in dry bulk trailers, railcars, storage tanks and the like for effectively introducing air intothe container or vessel to condition the material therein (pellets,pebbles, powders, etc.) to aid in the discharge thereof, and the deviceof the invention may equally as well be used with slurry solutions orliquids to maintain the same properly mixed. The aeration devices of thepresent invention are positioned in the container or hopper wall at apredetermined height above the outlet from the container or hopper,depending on the characteristics of the material stored therein and thenumber of devices used, and they provide an excellent unloading rate,with substantially 100% fluidization efficiency at all times, with noback pressure buildup with time.

In the present invention, a flexible, cone shaped member is secured on acomplementary shaped support within the container and air is caused toflow into the support and outwardly through openings beneath the coneshaped member to cause the cone shaped member to flutter or vibrate,which in turn causes the adjacent hopper wall or surface to vibrate, andthis vibration effects substantially complete removal of material fromthe container or hopper and also prevents bridging of material in thecontainer or hopper. The vibration effect increases as the level ofproduct in the container falls to a position near the aeration devicesor as a bridge develops in the product above the aeration devices. Thecone shape of the aeration device of the present invention enables anoptimum air flowback pressure curve to be obtained for most effectiveuniform aeration. Moreover, the material of the flexible cone shapedmember does not absorb product dust and moisture and permits interiorwashing of the hopper without necessitating drying of the cone. The conewill not take a permanent set or lose its elasticity and is not subjectto deterioration or product back flow, and will not retard product flowoff the hopper wall. Further, with the present invention, condition ofthe cone can be quickly visually ascertained and it can be removed andreplaced in a hopper in a matter of minutes without requiring tools.Still further, the aeration device of the invention is easilyinterchangeable on hoppers with conical bottoms, and the flexible coneis 2 the only part requiring replacement, thus reducing parts inventory.With the aeration device of the present invention, a

' mechanically controlled air flow back pressure relationship can beestablished, and it is not necessary to depend on a fabric weaveandporosity and the like, which can vary. Moreover, with the presentinvention air is directed towards the container surface to move andaerate the material therein with much greater efficiency than prior artdevices, and the aeration device of the present invention is notsusceptible to clogging, as is fabric.

Further, the present invention serves as a positive check valve toprevent product backup and plugging, whether the product is dry, aslurry or a liquid, and the aeration device of the present invention maybe easily cleaned, checked and replaced, and the flexible, cone shapedflap of the invention is held in place by the natural resiliency of thematerial positioned over the conically shaped support member, and noclamps or other securing devices are needed. The fluttering or vibrationof the flexible, cone shaped member or flap develops a sonic andvibration effect during certain critical phases of material transfer,thus improving the flow and cleaning out of material from the container.

OBJECTS OF THE INVENTION It is an object of this invention to provide anaeration device which functions as a check valve against backflow ofproduct and which can be located in the best position for efficienttransfer of product, and wherein the device directs air towardl thecontainer wall for most efflcient aeration of the material stored in thecontainer, and the cone shaped flap of the present invention vibratesduring certain critical phases of unloading of material from thecontainer to insure substantially complete removal" of material from thecontainer and to prevent bridging of material in the container.

Another object of the invention is to provide a method of assisting thedischarge of material from a container wherein air is discharged towardan inner surface of the container and into the material to fluidize thematerial, and inducing vibration in the container upon the occurrence ofcertain conditions to eliminate bridging of the material inthe:container and to insure thorough clean out of material from thecontainer.

BRIEF DESCRIPTION. OF THE DRAWINGS FIG. 1 is a perspective view, withportions broken away, of a hopper having aeration devices according tothe present invention mounted therein.

FIG. 2 is an enlarged, exploded, sectional view of the aeration deviceof the present invention.

FIG. 3 is an assembled sectional view of the device of FIG. 2, takenalong line 3-3 in FIG. 1.

FIG. 4 is a sectional view taken along line 4-4 of FIG. 2.

FIGS. 5-8 are diagrammatic views of various stages of discharge of a drybulk material from a container.

FIGS. 9 and 10 are diagrammatic views of various stages of discharge ofa slurry solution from a container.

DETAILED DESCRIPTION OF THE INVENTION In the drawings, wherein likereference numerals indicate like parts throughout the several views, ahopper or container H has a conically shaped bottom B with a-dischargeopening at its lower end leading into a discharge control valve V whichcontrols discharge of material from the hopper into a transverselyextending discharge line L. A plurality of aeration devices 10, inaccordance with the invention, are mounted to the conical bottom B ofthe hopper H above the discharge opening 0 in the hopper and spacedsubstantially equadistantly around the bottom. An air supply conduit Cis connected with each aeration device and with a main supply hose orconduit S connected with a suitable source of air under pressure (notshown).

Each aeration device 10 comprises a valve member 11 secured adjacent theinner surface of the bottom of the hopper, and each valve member 11includes a generally arrow shaped, hollow body or support 12 having asubstantially conically shaped portion 13 with a diametrically enlargedbase or end wall 14 at one end thereof, and a reduced diameter,cylindrical extension 15 at the other end thereof. A plurality ofradially extending openings 16 extend through the wall of conicalportion 13 for flow of air from the body 12 to the interior of thehopper H. A radially outwardly extending flange 17 is formed on the endof the cylindrical extension 15 of body 12, and a cylindrical, axiallyextending projection or extension 18 is ,on the other end or base of thebody 12 and extends outwardly through an opening 0' in the side of thebottom B of hopper H. The extension 18 has a bore 19 extending axiallytherethrough, and a plurality of inlet openings 20 extend through theside of extension 18 for flow of air from the conduit C and into thehollow interior of the body 12. The lower end of extension 18 is closedat 21 and is internally threaded at 22. 1 j A substantially conicallyshaped, flexible valve flap 23 has a substantially conically shaped sidewall 24 disposed in close fitting, overlying relationshipto the outersurface of conical portion 13 of body 12,.and closes the openings 16through the side of body 12. The valve flap 23 has a relatively large,open lower end 25, which is adaptedto flex toward and away from the sideof portion 13 of body 12 to control flow of air through the openings 16,as indicated in phantom line FIG. 3, for example. The valve flap 23 hasa relatively short, cylindrical extension26 on the other end thereof,with a radially inwardly projecting flange 27 in the open endofextension 26 said flange 27 being engaged behind the radiallyoutwardly extending flange 17 of body 12, to securely position andretain the valve flap 23 in position on the body 12.

A substantially cup shaped, hollow valve retainer and inlet fitting 28is positioned on the outside of bottom B of hopper H, and has a closedend 29 with an axially extending opening 30 ,therethrough, and an openend 31, and a slightly concave annular end surface 32. A radiallyextending inlet nipple or fitting 33 projects from one side of theretainer 29 and has a bore .34 therethrough for flow of air from theconduit C to the interior of container 29 and thence into the extension18 of body l2 and through the interior of the body and outwardly throughthe openings 16 to the interior of the hopper H. An annular sealinggasket 35 is disposed between the end surface 32 of retainer 29 and theouter surface of the bottom B of hopper H to seal the inlet fitting andretainer 28 relative to the hopper around the opening 0'.

-A valve fastener 36 has an elongate shaft threaded externally at 37 andslidably received through opening 30 in the valve retainer and inletfitting 28 and thread- 4 ably engaged in the internally threaded portion22 of body 12 tosecurely draw the body 12 toward the innersurfaceofbottom B of hopper H and to thus clamp the bottomm B betweenthe end 14 of body 12 and the sealing gasket and end surface of valveretainer and inlet fitting 28 to securely and accurately position theaeration devices 10 in the hopper. A handle 38 is connected with theshaft 36 to rotate the shaft to selectively fasten and release the body12 and valve retainer and inlet fitting 28.

In one specific embodiment of an aeration device in accordance with theinvention, the generally arrow shaped body 12 has an overall length ofapproximately 6 inches, and an overall or maximum diameter ofapproximately 4 inches. The conical portion 13 of the body is inclinedat an angle of approximately 33 relative to the axis and the body 12 hasa wall thickness of approximately 3/16 of an inch.

In FIGS. 5-8, various stages of operation of the device are illustrated.In FIG. 5, a container or hopper H is filled with a dry bulk material Mand has a plurality of aeration devices 10, in accordance with theinvention, secured in the bottom B thereof. A supply conduit S isconnected with a suitable source of air under pressure (not shown) andwith the conduits C connected with the respective aeration devices 10.The bottom of hopper H is connected with the discharge line L and theflow of material from the hopper to the discharge line L is controlledby valve V. A conduit Cl is also connected with the supply conduit S andwith the top of hopper H above the material therein and flow of airthrough this conduit is controlled by a valve V1. A valve V2 is alsoconnected in the line L to control flow 'of air from the source to thedischarge line L. As seen in FIG. 5, valves V1 and V2 are closed, andvalve V is closed, and air is flowing from the supply conduit S throughthe conduits C and through the aeration devices 10 and into the materialM in the hopper H. The

cone shaped aeration devices cause the air to flow first toward thehopper sides and then into the material to effectively and efficientlyaerate the material M.

In FIG. 6, valves V and V2 are opened and material is flowing from thehopper into the discharge line L. The material is maintainedin athoroughly fluidized condition by the flow of air through the aerationdevices 10.

In FIG. 7, the material M is substantially depleted and the level of thematerial is slightly above the level of the aeration devices 10. Whenthe material has reached approximately this level in the hopper H, theflexible valve flaps 23 are caused to vibrate by the flow of air fromtherebeneath and the vibration of the flaps induces vibration of thebottom B of the hopper H, thus resulting in substantially completeremoval of the material M from the hopper without any of the materialclinging to the hopper sides. This vibration effect also effectivelyprevents any bridging of material in the hopper during discharge of thematerial therefrom.

The hopper is seen in FIG. 8 completely empty of material and the flowof air through the aeration devices is inducing vibration in the bottomof the hopper to effect complete cleanout of material from the hopper.

In FIG. 9 and- FIG. 10, use of the invention with a slurry solution isdiagrammatically illustrated, and in FIG. 9, the device is shown at restand the heavy particles P in the slurry solution have settled out to thebottom of the hopper.

In FIG. 10, air is caused to flow from a suitable source through theconduits C and aeration devices into the slurry solution in the hopperto thoroughly mix the particles with the liquid of the slurry.

Flow of material from the hopper l-l may be aided by opening the valveV1 and causing flow of pressurized air from the source S through conduitC to the hopper on top of the material therein, if desired, or flow ofmaterial or slurry from the hopper may be accomplished by gravity orsuction pump or other suitable means, as desired.

The aeration device of the present invention may be quickly and easilymounted in existing installations, as for example, in the devicesdisclosed in U.S. Pat. Nos. 3,152,842 and 3,343,888, or it may beprovided in new installations, and the device may be manufactured fromany suitable materials, such as plastic, metal, and the like.

Further, the device is quiet and efficient in operation, and use of thedevice of the invention results in unloading of containers in a muchshorter time than heretofor possible, with resultant savings in time andmoney.

As this invention may be embodied in several forms without departingfrom the spirit or essential characteristics thereof, the presentembodiment is therefore illustrative and not restirctive, since thescope of the invention is defined by the appended claims rather than bythe description preceding them, and all changes that fall within themetes and bounds of the claims or that form their functional as well asconjointly cooperative equivalents are, therefore, intended to beembraced by those claims.

I claim:

1. An aeration device for assisting discharge of material fromcontainers, comprising a cone shaped support means having a smalldiameter end and a large diameter end and adapted to be affixed to awall of a container with the large end thereof adjacent the interior ofthe container wall and the small diameter end extending into theinterior of the container, said support means having an air inletadjacent the large diameter end thereof adapted to be connected to asource of air exteriorly of the container, and an air outlet interiorlyof the container, a flexible, cone shaped flap correspondingly shaped tothe support and having a small diameter end fixed on the small diameterend of the support means and extending in close fitting relationship tothe support means and closing said air outlet, the large diameter end ofthe flap disposed adjacent the container wall when the device is inoperative position and said large diameter end of the flap being free ofattachment to said support means for flexing movement thereof toward andaway from the support means to close and open said air outlet, wherebywhen said device is used, flow of air through said support means andoutwardly through said outlet induces flexation of said large diameterend of said flap away from said support means and flow of air outwardlyrelative to the axis of the support and toward the container wall andinto material stored in the container to aerate the material, theflexibility of said flap being such that it is caused to flutter orvibrate by air flowing therepast to agitate material in the containerand prevent bridging of the material in the container and to insuresubstantially complete removal of the material from the container.

2. An aeration device as in claim 1, wherein said aeration device ismounted in a bottom of a container, and said support means comprises ahollow, substantially arrow shaped body having a generally conicallyshaped portion with an inner end projecting into the interior of thecontainer and a diametrically enlarged base end engaged with an innersurface portion of the bottom of the container, an axially projectingextension on the base end and extended through an opening in the bottomof the container to exteriorly of the container, and fastening means onthe outside of the container engaged with the support means to securelymaintain the support means against the inner surface of the bottom ofthe container.

3. An aeration device as in claim 2, wherein a radially enlarged annularflange is on the inner end of the body and said flexible flap has asmall diameter end resiliently engaged behind the flange on the body toretain the flap in position on the body.

4. An aeration device as in claim 2, wherein said fastening meansincludes a cup shaped housing engaged against the outer surface of thebottom of the container and in surrounding relation to the extension onthe body, an inlet fitting on the cup shaped member for attachmentthereto of a suitable source of air under pressure, and a threadedfastener extended through an opening in the cup shaped member intothreaded engagement with the extension of the body to draw the extensionand cup shaped member toward one another on opposite sides of the bottomof the container to securely position the aeration device in thecontainer.

5. An aeration device as in claim 2, wherein a plural ity of saidaeration devices are mounted in the bottom of the container in equallyspaced relationship to one another.

6. An aeration device as in claim 2, wherein said body has a shortcylindrical extension at the inner end thereof with a radially outwardextending annular flange on the end of the extension, said flexible flaphaving a small diameter end with a short cylindrical portion disposed insnug fitting surrounding relation to the cylindrical portion of the bodyand resiliently engaged behind said flange to maintain said flap inposition on said body.

1. An aeration device for assisting discharge of material fromcontainers, comprising a cone shaped support means having a smalldiameter end and a large diameter end and adapted to be affixed to awall of a container with the large end thereof adjacent the interior ofthe container wall and the small diameter end extending into theinterior of the container, said support means having an air inletadjacent the large diameter end thereof adapted to be connected to asource of air exteriorly of the container, and an air outlet interiorlyof the container, a flexible, cone shaped flap correspondingly shaped tothe support and having a small diameter end fixed on the small diameterend of the support means and extending in close fitting relationship tothe support means and closing said air outlet, the large diameter end ofthe flap disposed adjacent the container wall when the device is inoperative position and said large diameter end of the flap being free ofattachment to said support means for flexing movement thereof toward andaway from the support means to close and open said air outlet, wherebywhen said device is used, flow of air through said support means andoutwardly through said outlet induces flexation of said large diameterend of said flap away from said support means and flow of air outwardlyrelative to the axis of the support and toward the container wall andinto material stored in the container to aerate the material, theflexibility of said flap being such that it is caused to flutter orvibrate by air flowing therepast to agitate material in the containerand prevent bridging of the material in the container and to insuresubstantially complete removal of the material from the container.
 2. Anaeration device as in claim 1, wherein said aeration device is mountedin a bottom of a container, and said support means comprises a hollow,substantially arrow shaped body having a generally conically shapedportion with an inner end projecting into the interior of the containerand a diametrically enlarged base end engaged with an inner surfaceportion of the bottom of the container, an axially projecting extensionon the base end and extended through an opening in the bottom of thecontainer to exteriorly of the container, and fastening means on theoutside of the container engaged with the support means to securelymaintain the support means against the inner surface of the bottom ofthe container.
 3. An aeration device as in claim 2, wherein a radiallyenlarged annular flange is on the inner end of the body and saidflexible flap has a small diameter end resiliently engaged behind Theflange on the body to retain the flap in position on the body.
 4. Anaeration device as in claim 2, wherein said fastening means includes acup shaped housing engaged against the outer surface of the bottom ofthe container and in surrounding relation to the extension on the body,an inlet fitting on the cup shaped member for attachment thereto of asuitable source of air under pressure, and a threaded fastener extendedthrough an opening in the cup shaped member into threaded engagementwith the extension of the body to draw the extension and cup shapedmember toward one another on opposite sides of the bottom of thecontainer to securely position the aeration device in the container. 5.An aeration device as in claim 2, wherein a plurality of said aerationdevices are mounted in the bottom of the container in equally spacedrelationship to one another.
 6. An aeration device as in claim 2,wherein said body has a short cylindrical extension at the inner endthereof with a radially outward extending annular flange on the end ofthe extension, said flexible flap having a small diameter end with ashort cylindrical portion disposed in snug fitting surrounding relationto the cylindrical portion of the body and resiliently engaged behindsaid flange to maintain said flap in position on said body.